Railway bolster re-enforcement system

ABSTRACT

Bolster re-enforcement systems, applicable both to new and existing bolster designs, provide for prestressing the bottom bolster center plate region in opposition to the stress pattern applied to the center region of the bolster as the result of vertical loading associated with normal operating conditions.

United States Patent 1191 11 1 3,924,542

Mac Donnell et al. Dec. 9, 1975 RAILWAY BOLSTER RIB-ENFORCEMENT 537,671 5/1895 Case 105/229 SYSTEM 671,119 5/1901 Stimson 105/228 689,611 12/1901 Hagemeier.. 1 Inventors: Robert Mac onn Crete; Otto 756,920 4/1904 Washburn... 105/229 A. Shander, Chicago Heights, both 820,338 5/1906 Barnes 105/229 of I11. 905,938 12/1908 Scott 105/229 2,716,864 9/1955 Hacker 52/225 X Asslgneei Mac Company, Crete, 3,4s2,531 12/1969 Tack 105/229 x [22] Filed: May 22, 1974 [2 1 App} 472 42 Primary Examiner-M. Henson Wood, Jr.

Assistant Examiner-Howard Beltran [52] US. Cl. 105/226; 52/225; 52/720;

85/50 R; 105/230; 403/43 [57] ABSTRACT [51] Int. Cl. B6lF l/l2; B61F 5/04; B61F 5/50;

F16B 43/02 Bolster re-enforcement systems, applicable both to [58] Field of Search 52/225, 226, 720; 85/50 R; new and existing bolster designs, provide for prestress- 105/226, 227, 228, 229, 230; 403/43, 44, 45, ing the bottom bolster center plate region in opposi- 46, 47, 48 tion to the stress pattern applied to the center region of the bolster as the result of vertical loading associ- [56] References Cited ated with normal operating conditions.

UNITED STATES PATENTS 25 CM 32 M 475,023 5/1892 Schoen 105/226 wmg gm-es US. Patent Dec. 9 1975 Sheet 1 of 8 3,924,542

US. Patent D.9 1975 I Sheet20f8 3,924,542

W H H 236 FIG. 7 Q Mk 2% FIG. 9

US. Patent Dec. 9 1975 Sheet 3 of8 3,924,542

F I G. I2 230 US. Patent Dec.91975 Shet4 of8 3,924,542

US. Patent Dec. 9 1975 Sheet 5 of8 3,924,542

5 wk A23 FIG.

FIG. 20

U.S. Pateant Dec. 9 1975 Sheet 6 of8 3,924,542

U.S. Patent Dec. 9 1975 Sheet 7 of8 3,924,542

U.S. Patent Dec. 9 1975 B \lllllllll\\\\\\\\ I FIG. 30

Sheet 8 0f 8 RAILWAY BOLSTER RE-ENFORCEMENT SYSTEM BACKGROUND OF THE INVENTION This invention relates to re-enforcement of truck bolsters against bending stresses, particularly those bending stresses resulting from conventional center plate loading under actual operating conditions.

The invention has application to improvements in the arrangement and fabrication of new bolsters and also has application to numerous types of existing bolsters. Generally speaking, the older the bolster, the more need exists for re-enforcement of the center plate area against bending stresses associated with normal operating conditions. Excessive stresses cause cracking and ultimately lead to actual breaking of the bolster.

In the case of very old bolsters, for example or years or more, excessive bending stresses have resulted in cracking at the lower center plate region more than at any other region. In the case of more recent bolsters, excessive bending stresses have produced cracks at the top region of the center plate more than at the bottom region. Possibly design changes incorporated in the more recent bolsters were intended to correct the crack problem at the bottom but such design changes have not removed the source of the problem of cracking.

The bolster cracking and breaking problem has accelerated in recent years and is undoubtedly aggravated by the fact that the operating speeds have been increased, the road beds have deteriorated, and the cars frequently carry greater loads than were anticipated when the bolsters were originally built.

The seriousness of the problem of bolster cracking cannot be overstated. There are times when a bolster upon developing a crack may be continued in service either because the existence of the crack is unknown or because no replacement is available. However, in nearly every case when a crack in a bolster breaks completely through, the broken bolster parts will hang down and catch against the ties and probably cause a derailment. The seriousness of a derailment depends upon the conditions at the time when the bolster breaks but the bolster is more likely to break under highspeed, heavy load conditions than at other times.

In summary, it now appears that the most important need for re-enforcement of bolsters exists in the case of the existing bolsters, not only because present operating conditions were not foreseen at the time such bolsters were designed, but also because of the difficulty and cost of replacing the entire group of existing bolsters.

There is, in addition, an important need for identifying the real cause of bolster failures so that new bolsters may be equipped with proper facilities for minimizing the cost for providing necessary re-enforc ement against excessive bending stresses.

SUMMARY OF THE INVENTION The present invention provides for prestressing the bolster center plate region in opposition to the stress pattern applied to the center region of the bolster by normal loading.

Upon application of the car load through the center plate, the bolster is flexed in the fashion of a simple beam supported at its ends and subjected to a central load so that the upper center plate region is subjected to compression and the lower center plate region is subjected to tension.

Thus, the prestressin g provided in accordance with this invention subjects the bottom center plate region of the bolster to precompression stress in substantial opposition to the tension which this region is subjected to under normal loading.

In the presently preferred practice of the present invention, a re-enforcement system is applied to the bottom central section of the bolster in a configuration tending to bend or bow the bolster upwardly to oppose downward bending caused by normal loading, thereby relieving the central region of substantial stresses until the normal loading greatly exceeds the prestressing introduced by the re-enforcement system. The reenforcement system of this invention comprises elongated, high-strength tension means extending crosswise of the bottom center section of the bolsterand anchored in lug means engaging the inclined bottom wall sections in flanking relation to the center section and means for securing the tension means under predetermined tension between the lug means for precompressing the bottom center section of the bolster. Where upward bowing is achieved, a vertical force is applied through the internal bolster ribs to the top center plate section of the bolster to reduce the likelihood of cracking at the top.

In the preferred embodiment, the re-enforcement system utilizes a high-strength tension means having bent ends that are adaptable to a range of inclined bottom wall angles and that enable an upward bowing prestressed effect while requiring a minimum of underside clearance.

In the application of the invention to the various types of existing bolsters, a number of special purpose embodiments are provided including one embodiment for minimizing underside clearance such as is required in sprung trucks and numerous embodiments utilizing various numbers and shapes for the tension means to adapt to the larger bolster sizes and to correct for the special failure modes known to exist with certain bolster designs.

The invention is also concerned with an improved new bolster design wherein lugs are formed integrally with the bolster specifically to accommodate a reenforcement system either as part of the original installation or after the bolster has been in use for a substantial time. In the case of new bolsters, in addition to the integral lugs, the invention is concerned with the arrangement of the internal center plate ribs of the bolster for more effectively developing the upward bowing action as part of the prestressing pattern produced by the re-enforcement system.

For any of the embodiments described above, the reenforcement system has the important advantage that if a crack does exist, the growth of the crack will be retarded. In addition, even if the crack were to break completely through, the bolster parts can be retained by the re-enforcement system to prevent a serious derailment.

Other features and advantages of the invention will be'apparent from the following description and claims and are illustrated in the accompanying drawings which show structure embodying preferred features of the present invention and the principles thereof, and what is now considered to be the best mode in which to apply these principles.

BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings forming a part of the specification, and in which like numerals are employed to designate like parts throughout the same:

FIG. 1 is a perspective view illustrating a bolster in association with the side frames of a railway car truck;

FIG. 2 is a top view showing the application of the reenforcement system to the bottom wall of a bolster;

FIG. 3 is a side view of the bolster showing the support system in place thereon;

FIG. 4 is a perspective view of a bolster end;

FIGS. 5 and 5A are perspective views of a universal type lug utilized for securing the tension unit of this invention on the bolster;

FIG. 6 is an exploded view of a nut and washer assembly for connecting the tension unit to the lugs;

FIG. 7 is an enlarged side view, partly broken away and sectioned to illustrate another bolster re-enforcement embodiment utilizing custom lugs particularly adapted for use with ribbed type bolster window treatments;

FIG. 8 is a perspective view of the lug used in the bolster reenforcement system shown in FIG. 7;

FIG. 9 is a side view showing a bolster of the non ribbed type equipped with a bolster reenforcement system using custom lugs;

FIG. 10 is a underneath perspective view of the lug suited particularly for the non-ribbed bolster window treatment;

FIG. 11 is an underneath perspective view showing a double rod reenforcement system applied to a heavy duty bolster;

FIG. 12 is a side view of the bolster and support system of FIG. 11;

FIG. 13 is a perspective view of the double rod bolster reenforcement embodiment of FIGS. 11 and 12;

FIG. 14 is a fragmentary underneath view of an integral lug bolster reenforcement system;

FIG. 15 is a side view partly broken away and sectioned illustrating the integral lug bolster reenforcement system of FIG. 14;

FIG. 15A shows an alternative of FIG. 15;

FIG. 16 is an enlarged sectional view taken as indicated on the line 16--16 on FIG. 15,

FIG. 17 is an enlarged broken fragmentary view of the bottom central region of a bolster illustrating an alternative integral lug arrangement;

FIG. 18 is a greatly enlarged fragmentary perspective view showing another type of integral lug bolster construction;

FIG. 19 is a side view partly broken away and sectioned illustrating an internal integral lug, straight support rod reenforcement system in accordance with this invention;

FIG. 20 is a similar side view broken away and sectioned to illustrate an external integral lug, straight support rod reenforcement system in accordance with this invention;

FIG. 21 is an underneath perspective view of a multiple straight support rod reenforcement system applied to a heavy duty bolster by separate lugs;

FIG. 22 is a perspective view of a triple support rod system wherein one of the rods is interior of the bolster;

FIG. 23 is a perspective view of a double support rod system wherein one of the rods is interior of the bolster;

FIG. 24 is an exploded perspective view illustrating another lug construction.

FIG. 25 is a side view partly sectioned and broken away showing a minimum clearance external reenforcement system on a bolster for a spring plank type truck;

FIG. 26 is a fragmentary bottom plan view of one end of the reenforcement system shown in FIG. 25;

FIG. 27 is a fragmentary view taken approximately as indicated on the line 2727 on FIG. 25;

FIG. 28 is a perspective view of the lug in the system of FIG. 25;

FIG. 29 is a sectional view taken on the line 29-29 of FIG. 28; i

FIG. 30 is a side view partly in section and broken away showing an alternative embodiment of a minimum clearance system similar to the FIG. 25 arrangement; and I I FIG. 31 is a fragmentary plan view of the reenforcement system shown in FIG. 30.

SPECIFIC DESCRIPTION Referring now to the drawings and particularly to FIG. 1, a conventional railway freight car truck arrangement is shown as including a pair of conventional side frames 20, 21 each having a bolster window that receives a separate spring group 22 for supporting opposite ends of a truck bolster B that extends between the side frames to support the car body.

A conventional truck bolster B, various details of which are shown in FIGS. 4 through 7 is a one-piece casting and comprises a substantially horizontal top wall 23 having a raised center plate portion 23C; a bottom wall 24 having a central horizontal portion 24C, longitudinally upwardly and outwardly angled intermediate wall portions 241 and horizontal spring seat wall portions 248; and a pair of vertical sidewalls 25 extending between the top and bottom walls to collectively define an elongated hollow body having maximum depth at the center. The outer ends of the side walls 25 are shown provided with the usual pairs of lugs 25L (see FIG. 4) that flank the vertical side frame columns to guide the bolster movement.

The hollow bolster body B, in the case of the existing types, includes various arrays of internal re-enforcement ribs. Suitable coring windows for framing the internal ribs are shown at 26 and 27 in the side walls and at W in the intermediate bottom wall portions 24L The windows 26 adjacent the center of the bolster body are arranged to accommodate brake rods.

In normal operation, the car load is applied to the top center plate section 23C and acts directly on the internal re-enforcing ribs 23I of the center plate section. Todays increased car loads and higher speeds of operation cause bolster center plate failures which usually begin as minor cracks either in the top or bottom of center plate region 23C or in the internal re-enforcing ribs 231 of the center plate or at the bottom center plate region 24C, depending upon the particular bolster design and the specific load condition. The cracks tend to begin at the bottom region 24C or in the ribs in the case of the older existing bolsters but the cracks tend to begin at the top or bottom of center region 23C in the case of the more recent bolsters wherein additional and/or stronger integral ribs were originally cast into the design.

Normal loading of the bolster causes vertical bending that places the top section including particularly the top wall of the bolster in compression and the bottom section including particularly the bottom wall in tension. The present invention concerns a bolster reenforcement and support system that provides additional strength to the bolster center plate section by application of tension means directly across the central horizontal wall portion 24C to prestress the center region of the bolster substantially oppositely to the stress pattern caused by normal loading.

The re-enforcement system of the invention has the additional advantage, in the case where the bolster to which it is applied already has a crack or develops a crack, of holding the bolster together in a fashion to limit extension of the crack. In the event the bolster breaks in half, the re-enforcement system prevents the bolster halves from dropping into contact with the road bed and thus helps to avoid a serious derailment.

As is described in greater detail a number of different bolster re-enforcement and support embodiments are disclosed to illustrate both preferred and alternative embodiments and also to illustrate specialized embodiments suited to the particular needs of the various types of existing bolsters. The designs of existing bolsters differ in a number of respects which affect the design of the bolster support system. For example, the angle of incline of the intermediate bottom wall sections 241 of the bolster varies from as little as a angle to as much as a 30 angle. It is preferable to utilize a re-enforcement and support system design which can handle a range of bolster angles in order to minimize part inventory problems and to maximize volume production advantages.

According to the invention all of the bolster reenforcement and support systems comprise elongated means arranged to reenforcement across the bottom central section of the bolster (for example in FIGS. 2-10, see the elongated rod 28); lug means engaging the inclined bottom wall sections in flanking relation to the bottom central section (for example see the lugs 29 projecting from the window openings W in the inclined bottom wall sections 241); and means are provided for securing the elongated means to the lugs (for example, see the nut and washer assemblies 30), such that the means is loaded to a pre-determined tension value thereby causing precompression of the bottom wall structure of the bolster.

The presently preferred embodiments as shown in FIGS. 2-10 are intended for 50 to 70 ton cars and includes elongated means 28 consisting of a single 1 inch diameter high strength rod, for example, 4140 heat treated steel rated at 150,000 PSI tensile. As shown the rod 28 has a bent form, in that its opposite ends 28E are bent to extend at a small angle with respect to the direction of its main length 28L. For the particular bolster illustrated, the inclined bolster walls 241 are assumed to have a 21 angle from horizontal and the rod ends 28E are bent to a angle. The 15 angle makes the rod 28 applicable to bolsters having inclined walls at any angle between 15 and 30. The 10 angle bolster structures involve special clearance requirements and are shown and described in connection with FIGS. 25 and 26.

A universal lug 29 as shown in FIGS. 5 and 5A for the embodiment of FIGS. 2 and 3 has an oversize elongated opening 295 to facilitate reception of the rod ends (for example, a 1% inch diameter hole for a linch diameter rod) and to allow for some differences in the angles of incline of the rod ends and the bolster walls.

The lug 29 of FIGS. 2 and 3 is for a single tension rod system but is described as universal because it fits 6 against the end of the window W for the known ribbing configurations for reenforcement of the window W. The lug is sized to fill the width of the window W but is small enough to be inserted through the bolster openings 26, 27.

The lug 29 has crosswings 29W at its upper outboard region to overhang the side edges of the mounting window W, there being sufficient cross section at the merger of the crosswings and the main body to accommodate the forces at this region. The lug has a rounded nose 29N that seats against the inboard edge of the bolster window W to apply the main load forces developed by the support system of this invention. In the universal lug, some degree of tipping of the lug in a vertical plane occurs to adapt to any angle differences between the rod ends and the bolster walls. Accordingly, the outboard face 29F of the universal lug may be flat. One or more flat filler washers 30F and one or more load indicating washers 30L may be employed between the face 29F and a lock nut 30N. The load washers 30L have raised sections on the surface facing the lock nut 30N. If accurate torque wrenches are not available, the load indicating washers 30L can be used with feeler gauges to set the desired initial torque load.

The lugs 29 for a ribbed bolster embodiment in FIGS. 7 and 8 are provided with vertically oversize elongated slots 29S that facilitate the insertion of the rod ends and also accommodate a fixed angle rod end 28E to bolsters having inclined walls at any angle within a range from 15 to 30. The lug 29 of FIGS. 7 and 8 has a curved outboard face 29F bordering the outer end of the elongated slot to act as a seat for a conical cast steel washer 30W that allows the rod end to adapt to various angles of the bolster walls 241. If desired one or more filler washers 30F and load indicating washers 30L may be inserted between the conical washer 30W and the lock nut SON.

In the ribbed bolster embodiment of FIGS. 7 and 8, the lugs 29 are generally T-shaped in end profile to present wings or shoulders 29W projecting beyond the edges of the mounting windows W. In addition, the lugs 29 have a boss 29B overhanging the enlarged inner edge of the bolster opening W and projecting towards the interior center rib structure of the bolster. An arcuate seat 29A on the lug casting engages the edge of the bolster window W. The arcuate seat 29 is curved in two dimensions, there being a vertical concave curvature enabling the lug to receive any thickness bolster wall and there being a horizontal convex curvature to mate with the curved end of the bolster window W.

The lugs 29 because of the side wings 29W and because of the presence of the boss 29B are inserted into the bolster window W by holding the lug generally transversely to the working position in which it is pictured.

To insert the lugs each lug is aligned with its wings 29W extending in the lengthwise direction of the bolster window W. The lug is then lifted upwardly until the wings 29W clear the bolster window. The lug is then rotated /2 turn and the boss 29B is tipped into the window so that the lug may be moved inwardly to seat against the slot end. The wings 29W act as a stop to lock the lug in its working position and the boss 29B serves as a re-enforc ement to retain the lug in place against downward forces that develop as a result of the interaction of the tension rod with the lug and the bolster.

For a non-ribbed bolster as shown in FIGS. 9 and 10, a simplified lug 29 is provided with a vertically oversize '7 elongated slot 298. The lug 29 has a curved nose or inboard face 29N and a flat outboard face 29F and is provided with an inboard semi-circular wing 29W that overhangs the edge of the bolster window W.

In both the ribbed and non-ribbed embodiments, the vertical slot 298 for receiving the tension rod has dimensions of about 1 inch in width and about 3 inches in height. This provides sufficient clearance to permit the bent rod to be fed through each casting slot.

It may be noted that the illustrated tension rod 28 is shown as round along its entire length; however, special rods can be utilized which are round and threaded on the bent ends 28E and flat along the main length 28L which underlies the bolster in order to minimize the clearance required for the installation. In this connection it should be noted that the design of the lug castings 29 is arranged so that the low point of the lug is at or above the bottom plane of the bolster. See FIG. 3.

From the foregoing it will be noted that the application of the bolster re-enforcement and support system using one 1 inch diameter tension rod 28 adds 125,000 lbs. of strength to the Bolster center plate area. In addition, if the bolster has a crack, the growth of the crack is retarded by the action of the tension rod and should the bolster fail at the center plate area, the tension rod and lugs will support it against dropping on to the road bed. Nevertheless the re-enforcement system is not intended as a substitute for a bolster and the bolster should be replaced should failure occur.

It should be noted that the system can be applied to any type of truck bolster having elongated slots on the inclined bottom bolster walls, providing that no special bottom clearance requirements exists. The installation may be effected on any repair track without need for special tools and without the need for welding or any modification of the bolster itself.

A special advantage of the preferred embodiment resides in the fact that the bent bolt 28, when placed under the tension, has itsmain length 28L in contact across the entire bottom face of the center section of the bolster while the bolt ends 28E, being at a angle, cause the bolt to exert an upward bending force across the bottom center of the bolster, thereby tending to reversely bow the bolster body. This type of prestressing pattern is substantially in opposition to that which results from normal loading applied to the bolster. Thus, the reverse bowing effect produced by the angled ends of the tension bolt not only causes precompression of the lower section of the bolster which is normally subjected to tension but it causes some pretensioning of the top section of the bolster which normally is subjected to compression. In the case of the more recent types of existing bolsters, center plate cracks are found to occur around the rim of the top or bottom of center plate section 23C. The described upward bowing effect produced by the bent bolts can produce greater strength at the top.

In addition to the bowing effect, as described, the

mounting of the lugs 29 in the bolster wall openings W causes the precompression stress which is applied to the lower section of the bolster to be distributed laterally so that the precompression at the bottom is not only transmitted directly through the bottom central wall of the bolster but also through the lower regions of the side walls 25. Thus, the precompression stresses derived from the tension rod are distributed through all of the bolster regions that require precompression. It should also be noted that in addition to the upward bowing forces produced by reason of the angle of the bolt ends, some of the forces transmitted into the bottom wall by the lugs induce upward vertical stresses in the adjacent internal bolster ribs 231 to directly support the top center plate section adjacent its periphery.

The bolster B shown in FIGS. 11 and 12 represents a bolster of the type used in ton and ton cars. A bolster reenforcement and support embodiment for the 100 and 125 ton car bolsters is shown in FIGS. 11 to 13 as including an elongated means consisting of a pair of tension rods 28 each having a main length 281. extend- 7 ing across the bottom center plate region 24C and bent ends 28E extending upwardly along the angled intermediate wall regions 241.

Lug means 32 are engaged in the window openings W and have a curvilinear lower body portion 32C provided with a pair of oversize elongated openings, a reduced neck portion 32R and an irregular upper body portion providing a curved nose 32N on the inboard face of the lug, and a pair of crosswings 32W extending laterally of the main body to overhang the edges of the window W. The outboard face 32F of the lug 32 is flat.

The lugs 32 are similar to their function and flexibility to the universal lugs 29 of FIGS. 2 and 3 except that each lug 32 has a pair of openings for the pair of tension rods. The lugs 32 are inserted from beneath by aligning the crosswings 32W with the window and r0,-

tating to the correct position after the crosswings are 7 raised above the bottom wall portions bordering the windows.

As previously described, a flat filler washer 30F, a load indicating washer 30F and a lock nut SON are applied to each projecting rod end. When all the lock nuts are fully torqued in place, a pair of 1 inch high strength tension rods impart an additional strength to the bolster of about 250,000 lbs. The initial load applied to the lugs is preferably at points above the bottom center region of the bolster and the tension rods directly contacts the bolster to develop an upward bowing for more fully compensating for the normal loading stresses. Typically, each lock nut is torqued to about 1,250 foot pounds. This can be done with torque wrenches or by the use of feeler gauges with the load indicating washers.

Another important aspect of the invention involves the utilization of the bolster re-enforcement and support system in the context of a newly designed bolster. Accordingly, there is shown in FIGS. 14 to 16 a new type of bolster construction particularly intended to receive an elongated tension means. The new bolster B is generally similar to existing bolsters as already described in connection with FIGS. 2 to 10 and corresponding parts bear the same reference number in the 100 series as compared with the embodiments of FIGS. 2 to 10. It will be noted in particular that the lugs 129 for receiving the bent bolts 128 are formed integrally with the one-piece bolster and are shown to project downwardly from the inboard end of the windows W in the inclined bottom walls of the bolster, the lugs define reception slots 1295 and have outboard faces serving as a seat for the filler washers 130E, loading indicating washers 130L and the lock nuts 130N which are torqued into place to develop the 'desiredlevel of precompression. The slots 1295 are shown open at the bottom to facilitate application of the bent rod 128 and the inclined wall of the bolster has thickened wall portions 124T bordering the sides and inner end of the bolster wall windows W in order to compensate for the-localized forces resulting from the pretensioning of the rod 128 between the lugs 129. In addition, the internal center rib structure is modified as illustrated in the ribs 123] are shown in flanking relation to the bolster opening, such ribs having a merger line with the bolster which is slightly outboard of the location of the lugs. When the load points of the nuts 130N on the lugs 129 are higher than the lower region of the bolster the modified rib structure effects a better distribution of the prestress pattern resulting from the reverse bowing effect produced by tensioning of the bolts.

An alternative integral lug embodiment is shown in FIG. A wherein the lugs 129' are located about 1 inch outward of the outboard edge of the window opening. This arrangement requires a longer bolt but it protects a broader region of the center of the bolster. The increased span aids the overall bolster strength and is easily made possible in the case of new bolsters where the lug location may be conveniently provided on either side of the bolster window.

The integral lug bolster allows the invention to be applied at minimum cost and with maximum standardization. The invention comtemplates that stress studies on new bolsters particularly concerned with optimizing the advantages of the prestress feature of this disclosure may shown a need for additional bolster modifications.

A number of other lug arrangements particularly for integral lug bolster designs are also contemplated. For example, integral lugs 129 are shown on lower regions of the side walls 125 in flanking relation to the lower bolster center plate region 124C to accommodate a pair of tension rods 128 in FIG. 17. Instead of the parallel integral lugs 129 that allow for vertical insertion of the bent tension rod as shown in FIG. 16, an angled lug 129A in combination with a straight lug 129 can be used as shown in FIG. 18 to provide for lateral insertion of the tension rod. Newly constructed integral lug bolsters facilitate matching of the bolster wall angles and the tension rod angles to permit accurate close fit mountings.

Other integral lug bolster embodiments are shown in FIGS. 19 and 20. In the arrangement of FIG. 19, pairs of parallel integral lugs 131 project upwardly of the inclined bottom wall portions 1241 at points bordering the inboard ends of the bolster windows W. The lugs 131 are shown with flat faces for the washers 130F, 130L and the nuts 130N and the tension rod 128 is shown extending straight through the lower interior region of the bolster. Some of the present day bolster designs have clearance at this region of the bolster so that interior rib arrangements that are practical for this application are already known.

When the rod 128 shown in FIG. 19 is tensioned by torquing the nuts 130N the precompression pattern is somewhat different because the main length of the rod is not applying a vertical force a the bottom center re- 10 and does not produce the upward force of the tension rod against the center region 124C but it effectively precompresses the center region 124C to improve the bolsters overall ability to withstand normal vertical loading without cracking and breaking.

Multi-rod bolster reenforcement and support systems for application to existing bolsters are shown in FIGS. 21 to 24. In FIG. 21, the bolster B is shown equipped with lugs 31 generally similar to the lug 29 shown in FIG. 8 except that each lug 31 has a pair of elongated openings located beneath the bottom plane of the bolster to receive a pair of straight tension rods 128. Thus, each of the lugs 31 has an inboard overhanging nose or boss and crosswings 131W that are inserted in the fashion described in FIG. 8. The outboard face of the lug is concave to serve as a seat for an arcuate double washer 132W which has a flat outboard face 132F to accommodate load indicating washers and lock nuts.

A three rod bolster reenforcement and support system is shown in FIG. 22 wherein each of the lugs 33 are similar to the lugs 31 shown in FIG. 21 except no cross wings are used (the corresponding parts being identified by the same reference numerals) and, in addition,

' each lug includes a top extension 33T having a concave gion 124C of the bolster. It is therefore desirable that g the interior ribs 1231 be arranged to increase the direct transmission of the preload forces to the upper center plate region 123C.

Another integral lug bolster embodiment is shown in FIG. 20 where the pairs of parallel integral lugs 129 project downwardly somewhat like the lugs shown in FIGS. 15. In FIG. 20, however, the lugs 129 are located closer to the center region 124C and extend to a lower elevation to receive a straight tension rod 128. This arrangement leaves less clearance beneath the bolster seat for an arcuate washer 32W to provide for mounting the third rod 128 to extend across the lower center region internally of the bolster.

Another combination tension rod arrangement is shown in .FIG. 23 wherein the lug 34 is of the same general type as shown in FIG. 22 but has its lower section arranged to receive only a single tension rod. Thus, the embodiment in FIG. 23 has one internal tension rod 128 and one external tension rod 128.

In the combination intemal-external embodiments of FIGS. 22 and 23 each tension rod may be torqued to the same value or a preferential torquing arrangement may be utilized wherein the external rods are torqued to the typical values previously given for producing the primary precompression effect while the internal tension rod is torqued substantially less so as to serve not primarily for precompression but for providing additional normal load handling capacity at the lower bolster center region.

Another lug configuration as shown at 35 in FIG. 24 may be utilized with the bolster support systems intended for existing bolsters. In this arrangement arcuate washer 36W has a counter sunk socket 368 for receiving a square lock nut 37 to show that where the tension rods are straight across the bottom of the bolster the precompression torquing may be applied from one end only by the use of counter sunk nuts in the lug at the opposite ends such as is shown in FIG. 24.

In addition, the lug arrangement shown in FIG. 24 has an apertured tail portion 35A serving as an anchor for a safety sling 37 which is connected through the bolster to retain the parts withthe bolster in the event a lug casting should break under unusual loading conditions.

In some instances the bolster mounting clearances are severely restricted such that a one inch diameter rod in contact with the underface of the bottom center region of the bolster cannot be accommodated. Such a situation is encountered in the case of a sprung truck, that is a truck which includes a spring plank. A bolster re-enforcement and support system, particularly useful for the low clearance spring plant type bolster mounting environment is shown in FIGS. 25 to 27 wherein the tension unit consists of a flat plate 38 having its oppo- 1 1 site ends secured to end castings 39 which are arranged to receive projecting cap screws 40 that serve as the counterpart to the rod ends of the bent rod embodiments.

To provide equivalent strength to that acheived with the one inch diameter tension rod the flat steel plate 38 is inches wide and A inches thick and is arranged to extend across the underface of the bottom center region 24C of the bolster and sufficiently therebeyond to afford clearance for the end castings 39. Each end casting 39 had an aperture main cross wall 39W provided with an oversize hole 39H, for example, a l 3/ 16th inch diameter hole to receive the threaded end of the cap screw 40 at various angular orientations to adapt the tension unit to bolsters having walls of various angular incline. Each of the end castings 39 has parallel attachment arms 39A extending therefrom and provided with notched edges 39E that receive the end of the steel plate. The end castings are welded to the plate so that the weld region 41 is at least as strong as the main section of the plate 38. For this purpose each of the end castings has contact with the plate, a distance of 3 A inches along each side of each attachment arm 39A to make a total of 14 inches of continuous A inch weld plus a fillet weld across each end of each arm 39A. The arms are shown herein being /8 inch wise.

The lugs 42 for receiving the threaded ends of the cap screws 40 are of angular generally L shaped profile, having a short leg 425 provided with an oversize aperture 42A that receives the threaded cap screw stud. The long leg 42L of each lug has a rounded nose 42N for broad surface engagement with the inboard edge of bolster window W and it includes cross wings 42W to overhang the edges of the wall portions that border the bolster window W to retain the lug in place. The underface of the long leg of the lug has a stepped profile so that the inboard or nose end thereof is located immediately adjacent the upper face of the corresponding end casting 39. These parts being engagable under load and tending to remain in the position as originally installed by reason of their interengagement. As indicated previously, the projecting end of the studs are provided with a filler washer 30F engagable against a flat outboard face 42F on the short leg of the lug, a load indicating washer 30L and a lock nut 30N.

The size and shape of the lugs 42 is such that they may be inserted either from the top or bottom of the bolster. The arrrangement is such that the plate 38 is substantially planar so that it contacts the central lower region 24C of the bolster and projects sufficiently along the inclined bolster walls 24I to extend beyond the inboard edge of the windows W. At the location there is sufficient clearance to accommodate the generally triangular shaped end castings 39 that receive the cap screws. The lugs 42 in this form are universal in that they are adaptable both to ribbed and nonribbed bolster window treatment, the lugs being elongated to insure that the connection of the tension unit is accomplished without any part projecting beneath the elevation of the plate.

Tests of the reenforcement system of FIGS. 25, 26 on a conventional 5 X 10, 50 ton bolster having a minimum static load requirement of 423,500 lbs. per AAR specifications showed that the reenforced bolster carried a load of 632,000 lbs. and failure finally developed at a location outboard of the lugs 42.

A modified reenforcement system for sprung trucks is shown in FIGS. 30 and 31 where the points of attach- 12 ment to the bolster are located outboard of the windows W. These outboard points of attachment develop prestressing both across the center plate area and across the secondary window areas that are reduced section by reason of the provision of the window openings 27, W.

The system of FIGS. 30 and 31 may be identified to the system of FIGS. 25 and 26 (corresponding parts being identified by the same reference characters) except that the welded attachment lugs 142 replace the angled lugs 42 and longer bolts are used in place of the bolts 40. The lugs 142 shown herein are identical to the end castings 39 and are secured to the underface of the bolster by lines of weld 141 to provide a total weld length equal to or greater than that of the weld lines 41.

The mounting location of the welded lugs 142 is best shown in FIG. 31 and it should be noted that the prestress forces are introduced into the inclined bolster walls 24I at locations that are largely outward of the outboard edges of the windows W.

The result is that the bolster is reenforced by prestressing substantially from spring seat to spring seat.

-The higher elevation of the points of attachment of the lugs 142 enhances the upward bowing effect of the reenforcement system.

If desired, the bolster may be heat treated after the welding of the lugs 142 to relieve any thermally reduced stresses at the weld region.

It is also contemplated that the welded lugs 142 or modifications thereof can be used with the bent bolt embodiments of FIGS. 2, 7 and 11, the only change being to use the bolts sufficiently long to span the greater lug spacing and to provide bolt holes large enough to facilitate insertion of the ends of the bent bolts.

In addition the integral lugs 129' shown in FIG. 15A should also be understood to be representative of a welded lug embodiment.

Thus, while preferred constructional features of the invention are embodied in the structure illustrated herein, it is to be understood that changes and variactions may be made by those skilled in the art without departing from the spirit and scope of the appended claims.

What is claimed is:

1. In a railway truck bolster structure that includes a hollow bolster body having an upper wall structure incorporating a top center plate section, a lower wall structure having a bottom central section flanked by upwardly and outwardly inclined intermediate bottom wall sections and horizontal spring seal wall sections merging with and extending outwardly from said inclined intermediate sections, and internal ribbing connecting said upper wall structure and said lower wall structure, an improved bolster re-enforcement comprising elongated means extending across said bottom central section, lug means engaging intermediate portions of said inclined intermediate bottom wall sections in flanking relation to said bottom central section and means for securing said tension means to said lug means under predetermined rension to precompress the bottom center section of the bottom wall.

2. In a bolster structure as defined in claim 1 wherein said elongated means is located beneath said bottom central section.

3. In a bolster structure as defined in claim 1 wherein said elongated means includes threaded rod ends, said lug means have openings to receive said threaded rod 13 ends, and said means for securing includes lock nuts on the outboard sides of the lug means and engaged on said threaded rod ends.

4. In a bolster structure as defined in claim 1 wherein said elongated means includes a horizontally extending main length section located beneath said bottom central section and upwardly inclined end sections extending along the upwardly inclined intermediate bottom wall sections to engage said lug means at points above the plane of said bottom central section for applying upward force to said main length section when said elongated means is in tension between said lug means.

5. In a bolster structure as defined in claim 1 wherein said elongated means is of rod-like form having a horizontally extending main length section located beneath said bottom central section and upwardly inclined end sections extending along the upwardly inclined intermediate bottom wall sections to engage said lug means at points above the plane of said bottom central section for applying upward force when said elongated means is in tension between said lug means.

6. In a bolster structure as defined in claim 5 wherein said elongated means is rigid and has threaded end sections, said lug means have vertically elongated slots opening downwardly to receive said threaded rod ends and said means for securing includes lock nuts on the outboard sides of the lug means and engaged on said threaded rod ends.

7. In a bolster structure as defined in claim 1 wherein said elongated means is of rod-like form and has at least one threaded rod end, the lug means corresponding to said one threaded rod end has an opening to receive the same and the means for securing includes a lock nut on the outboard side of the last named lug means and engaged on said one threaded rod end.

8. In a bolster structure as defined in claim 7 wherein the last-named lug means has an arcuate surface bordering said opening and facing said lock nut, a washer is disposed on said one threaded rod end between said nut and said lug means has a complementary arcuate surface seating in swiveled relation against said arcuate surface to compensate for a range of angles of the adjacent inclined bottom wall section.

9. In a bolster structure as defined in claim 7 wherein a load indicating washer is disposed on said one threaded rod end between said nut and the correspondingly means to indicate the level of tension load applied to said elongated means.

10. In a bolster structure as defined in claim 1 wherein at least one of said inclined intermediate wall sections has an elongated window opening extending outwardly therein and bordered by an inboard bolster edge region, and wherein at least one of said lug means has a main body having a through passage for said elongated means and having an inboard face that presents a confronting seat surface above said passage for contact with the inboard bolster edge region, and having an outboard face that presents a lower seat surface bordering said passage for contact with said means for securing.

11. In a bolster structure as defined in claim 1 wherein said elongated means includes a fiat plate extending beneath and beyond said bottom central section, end castings lap-welded to opposite ends of the flat plate and carrying threaded rod ends for engagement with said lug means and said means for securing.

12. In a bolster structure as defined in claim 1 wherein each of said inclined intermediate bottom wall 14 sections has an elongated window opening extending outwardly therein and bordered by inboard and outboard bolster edge regions, said lug means engaging said inclined intermediate bottom wall sections adjacent said elongated window openings.

13. In a bolster structure as defined in claim 12 wherein said lug means are integral with said inclined intermediate bottom wall sections and located adjacent the inboard bolster edge region of the window opening.

14. In a bolster structure as defined in claim 12 wherein said lug means are integral with said inclined intermediate bottom wall sections and located outward of the outboard bolster edge region of the window opening.

15. In a bolster structure as defined in claim 12 wherein said lug means have weld means securing said lugs to the inclined bottom wall sections outwardly of the outboard bolster edge region of the window openmg.

16. In a bolster structure as defined in claim 15 wherein said elongated means is of rod-like form having a horizontally extending main length section located beneath said bottom central section and upwardly inclined end sections extending along the upwardly inclined intermediate bottom wall sections to engage said lug means at points above the plane of said bottom central section for applying upward force when said elongated means is in tension between said lug means.

17. In a bolster structure as defined in claim 15 wherein said elongated means includes a flat plate extending beneath and beyond said bottom central section, end castings lap-welded to opposite ends of the flat plate and carrying threaded rod ends for engagement with said lug means and said means for securing.

18. A pre-stressible railway truck bolster structure comprising a hollow bolster body having an upper compression wall portion incorporating a top center plate section, a bottom tension wall portion having a bottom central section underlying said top center plate section and flanked by upwardly and outwardly extending inclined intermediate bottom wall sections and horizontal spring seat wall sections merging with and extending outwardly from said inclined intermediate sections, internal wall structures connecting said upper compression wall portion and said bottom tension portion and lug means engaging intermediate portions of said inclined intermediate bottom wall sections in flanking relation to said bottom central section and defining opposite regions of an elongated pathway that provides a mounting clearance therebetween, said lug means engaging said bolster structure to apply compression loading to said bottom central section for pre-stressing the bottom central section against bend stresses resulting from vertical loading of the top center plate section.

19. A pre-stressible bolster structure as defined in claim 18 wherein each of said inclined intermediate bottom wall sections has an elongated window opening extending outwardly therein and bordered by inboard and outboard bolster edge regions, said lug means integrally engaging said inclined intermediate bottom wall sections adjacent said elongated window openings.

20. A prestressible bolster structure as defined in claim 19 wherein said lug means merge with said inclined intermediate bottom wall sections adjacent the inboard bolster edge regions of the window openings.

21. A prestressible bolster structure as defined in claim 19 wherein said lug means merge with said inclined intermediate bottom wall sections adjacent the outboard bolster edge regions of the window openings.

22. A prestressible bolster structure as defined in claim 19 wherein at least some of said internal wall structures extend from the top center plate section and merge with said inclined intermediate bottom wall sections outwardly of said inboard bolster edge regions.

23. A tension unit for pre-compression a bottom center section of a bolster that has intermediate bottom wall portions leading in oppositely upwardly inclined relation from opposite extremities of said bottom center section and merging with horizontal spring seat wall sections that extend outwardly from said intermediate bottom wall portions, said tension unit comprising a horizontal main length section to extend fully across said bottom center section and having end sections leading from opposite extremes of said main length section and terminating in threaded rod portions directed in oppositely inclined relation from said main length section for applying load to said intermediate bottom wall portions, the direction angles of said threaded rod portions relative to said bottom center section being acute angles.

24. A tension unit as defined in claim 23 wherein said main length section comprises a flat plate and said end sections comprise end castings and lap-welded to opposite ends of the flat plate and carrying threaded rod ends. i

25. A tension unit as defined in claim 23 wherein said tension unit comprises an elongated rigid one-piece rod having a straight intermediate portion serving as the main length section and having correspondingly inclined end portions serving as said end sections.

UNITED STATES PATEL T OFFICE CERTIFICATE OF CORRECTION mus-r NO. 1 3,924,542

DATED December 9 1975 |NVENTOR(S) Robert W. MacDonnell and Otto A. Shander It is certified that error appears in the above-identified patent and that sard Letters Patent are hereby corrected as shown below:

Column 12, line 51; Strike out "seal" and insert ----seat-- Column 12, line 60; Strike out 'tension" and insert ---elongated- Column 12, line 61; Strike out "rension" and insert -tension-- Column 14 line 4; Before the second 'portion" insert wall---- Signed and fourth Day Of May 1976 [SEAL] Arrest:

RUTH C. MASON C. MARSHALL DAMN 198N718 /7 ('mnmissinnvr ufiarmls and Trudwrwrks 

1. In a railway truck bolster structure that includes a hollow bolster body having an upper wall structure incorporating a top center plate section, a lower wall structure having a bottom central section flanked by upwardly and outwardly inclined intermediate bottom wall sections and horizontal spring seal wall sections merging with and extending outwardly from said inclined intermediate sections, and internal ribbing connecting said upper wall structure and said lower wall structure, an improved bolster re-enforcement comprising elongated means extending across said bottom central section, lug means engaging intermediate portions of said inclined intermediate bottom wall sections in flanking relation to said bottom central section and means for securing said tension means to said lug means under predetermined rension to precompress the bottom center section of the bottom wall.
 2. In a bolster structure as defined in claim 1 wherein said elongated means is located beneath said bottom central section.
 3. In a bolster structure as defined in claim 1 wherein said elongated means includes threaded rod ends, said lug means have openings to receive said threaded rod ends, and said means for securing includes lock nuts on the outboard sides of the lug means and engaged on said threaded rod ends.
 4. In a bolster structure as defined in claim 1 wherein said elongated means includes a horizontally extending main length section located beneath said bottom central section and upwardly inclined end sections extending along the upwardly inclined intermediate bottom wall sections to engage said lug means at points above the plane of said bottom central section for applying upward force to said main length section when said elongated means is in tension between said lug means.
 5. In a bolster structure as defined in claim 1 wherein said elongated means is of rod-like form having a horizontally extending main length section located beneath said bottom central section and upwardly inclined end sections extending along the upwardly inclined intermediate bottom wall sections to engage said lug means at points above the plane of said bottom central section for applying upward foRce when said elongated means is in tension between said lug means.
 6. In a bolster structure as defined in claim 5 wherein said elongated means is rigid and has threaded end sections, said lug means have vertically elongated slots opening downwardly to receive said threaded rod ends and said means for securing includes lock nuts on the outboard sides of the lug means and engaged on said threaded rod ends.
 7. In a bolster structure as defined in claim 1 wherein said elongated means is of rod-like form and has at least one threaded rod end, the lug means corresponding to said one threaded rod end has an opening to receive the same and the means for securing includes a lock nut on the outboard side of the last named lug means and engaged on said one threaded rod end.
 8. In a bolster structure as defined in claim 7 wherein the last-named lug means has an arcuate surface bordering said opening and facing said lock nut, a washer is disposed on said one threaded rod end between said nut and said lug means has a complementary arcuate surface seating in swiveled relation against said arcuate surface to compensate for a range of angles of the adjacent inclined bottom wall section.
 9. In a bolster structure as defined in claim 7 wherein a load indicating washer is disposed on said one threaded rod end between said nut and the correspondingly means to indicate the level of tension load applied to said elongated means.
 10. In a bolster structure as defined in claim 1 wherein at least one of said inclined intermediate wall sections has an elongated window opening extending outwardly therein and bordered by an inboard bolster edge region, and wherein at least one of said lug means has a main body having a through passage for said elongated means and having an inboard face that presents a confronting seat surface above said passage for contact with the inboard bolster edge region, and having an outboard face that presents a lower seat surface bordering said passage for contact with said means for securing.
 11. In a bolster structure as defined in claim 1 wherein said elongated means includes a flat plate extending beneath and beyond said bottom central section, end castings lap-welded to opposite ends of the flat plate and carrying threaded rod ends for engagement with said lug means and said means for securing.
 12. In a bolster structure as defined in claim 1 wherein each of said inclined intermediate bottom wall sections has an elongated window opening extending outwardly therein and bordered by inboard and outboard bolster edge regions, said lug means engaging said inclined intermediate bottom wall sections adjacent said elongated window openings.
 13. In a bolster structure as defined in claim 12 wherein said lug means are integral with said inclined intermediate bottom wall sections and located adjacent the inboard bolster edge region of the window opening.
 14. In a bolster structure as defined in claim 12 wherein said lug means are integral with said inclined intermediate bottom wall sections and located outward of the outboard bolster edge region of the window opening.
 15. In a bolster structure as defined in claim 12 wherein said lug means have weld means securing said lugs to the inclined bottom wall sections outwardly of the outboard bolster edge region of the window opening.
 16. In a bolster structure as defined in claim 15 wherein said elongated means is of rod-like form having a horizontally extending main length section located beneath said bottom central section and upwardly inclined end sections extending along the upwardly inclined intermediate bottom wall sections to engage said lug means at points above the plane of said bottom central section for applying upward force when said elongated means is in tension between said lug means.
 17. In a bolster structure as defined in claim 15 wherein said elongated means includes a flat plate extending beneath and beyond said bottom central section, end castings lap-welded to opposite ends of the flat plaTe and carrying threaded rod ends for engagement with said lug means and said means for securing.
 18. A pre-stressible railway truck bolster structure comprising a hollow bolster body having an upper compression wall portion incorporating a top center plate section, a bottom tension wall portion having a bottom central section underlying said top center plate section and flanked by upwardly and outwardly extending inclined intermediate bottom wall sections and horizontal spring seat wall sections merging with and extending outwardly from said inclined intermediate sections, internal wall structures connecting said upper compression wall portion and said bottom tension portion and lug means engaging intermediate portions of said inclined intermediate bottom wall sections in flanking relation to said bottom central section and defining opposite regions of an elongated pathway that provides a mounting clearance therebetween, said lug means engaging said bolster structure to apply compression loading to said bottom central section for pre-stressing the bottom central section against bend stresses resulting from vertical loading of the top center plate section.
 19. A pre-stressible bolster structure as defined in claim 18 wherein each of said inclined intermediate bottom wall sections has an elongated window opening extending outwardly therein and bordered by inboard and outboard bolster edge regions, said lug means integrally engaging said inclined intermediate bottom wall sections adjacent said elongated window openings.
 20. A prestressible bolster structure as defined in claim 19 wherein said lug means merge with said inclined intermediate bottom wall sections adjacent the inboard bolster edge regions of the window openings.
 21. A prestressible bolster structure as defined in claim 19 wherein said lug means merge with said inclined intermediate bottom wall sections adjacent the outboard bolster edge regions of the window openings.
 22. A prestressible bolster structure as defined in claim 19 wherein at least some of said internal wall structures extend from the top center plate section and merge with said inclined intermediate bottom wall sections outwardly of said inboard bolster edge regions.
 23. A tension unit for pre-compression a bottom center section of a bolster that has intermediate bottom wall portions leading in oppositely upwardly inclined relation from opposite extremities of said bottom center section and merging with horizontal spring seat wall sections that extend outwardly from said intermediate bottom wall portions, said tension unit comprising a horizontal main length section to extend fully across said bottom center section and having end sections leading from opposite extremes of said main length section and terminating in threaded rod portions directed in oppositely inclined relation from said main length section for applying load to said intermediate bottom wall portions, the direction angles of said threaded rod portions relative to said bottom center section being acute angles.
 24. A tension unit as defined in claim 23 wherein said main length section comprises a flat plate and said end sections comprise end castings and lap-welded to opposite ends of the flat plate and carrying threaded rod ends.
 25. A tension unit as defined in claim 23 wherein said tension unit comprises an elongated rigid one-piece rod having a straight intermediate portion serving as the main length section and having correspondingly inclined end portions serving as said end sections. 